Washable, waterproof, sealable and reusable soft gusseted volumized storage bags

ABSTRACT

Disclosed are embodiments of a volume control storage bag and methods of making same. The volume control storage bag may have first and second sidewalls, a double-locking closure mechanism with a first closure element extending along the first sidewall and a second closure element extending along the second sidewall, each closure element having a channel and an elongated member configured for interlocking with one another. A gusset is sealed along three sides of the first and second sidewalls, leaving an opening through the closure mechanism and defining an interior space having a specific volume. Corner seals may be formed at the corners of the first and second sidewalls, further reinforcing the double-locking closure mechanism for an airtight and hence waterproof seal. The volume control storage bag may be made of a food-grade polyethylene vinyl acetate blend, approximately 90% or less ethylene vinyl acetate and approximately 10% or less polyethylene.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of, and claims a benefit of priorityfrom U.S. patent application Ser. No. 14/598,511, filed Jan. 16, 2015,issued as U.S. Pat. No. 11,097,505, entitled “WASHABLE, WATERPROOF,SEALABLE AND REUSABLE SOFT GUSSETED VOLUMIZED STORAGE BAGS,” whichclaims a benefit of priority from U.S. Provisional Application No.61/928,579, filed Jan. 17, 2014, entitled “WASHABLE, WATERPROOF,SEALABLE AND REUSABLE SOFT GUSSETED VOLUMIZED STORAGE BAGS.” Thisapplication relates to U.S. patent application Ser. No. 17/027,558,filed Sep. 21, 2020, entitled “WASHABLE, WATERPROOF, SEALABLE ANDREUSABLE STORAGE BAGS,” which is a continuation of, and claims a benefitof priority from, U.S. patent application Ser. No. 15/997,360, filedJun. 4, 2018, issued as U.S. Pat. No. 10,780,666, entitled “WASHABLE,WATERPROOF, SEALABLE AND REUSABLE STORAGE BAGS,” which is a divisionalof, and claims a benefit of priority from, U.S. patent application Ser.No. 14/598,475, filed Jan. 16, 2015, issued as U.S. Pat. No. 10,000,033,entitled “WASHABLE, WATERPROOF, SEALABLE AND REUSABLE STORAGE BAGS,”which claims a benefit of priority from U.S. Provisional Application No.61/928,575, filed Jan. 17, 2014, entitled “WASHABLE, WATERPROOF,SEALABLE AND REUSABLE STORAGE BAGS,” which relates to U.S. patentapplication Ser. No. 29/489,790, filed May 2, 2014, issued as U.S. Pat.No. D753,444, entitled “COMBINED STORAGE AND SNACK BAG WHICH ISREUSABLE, WASHABLE AND SEALABLE.” All applications listed in thisparagraph are hereby fully incorporated by reference herein.

TECHNICAL FIELD

This disclosure relates generally to storage containers. Moreparticularly, embodiments disclosed herein relate to lightweight,sealable, volume control, and reusable storage containers, useful in avariety of container categories, including food, travel, andorganization.

BACKGROUND OF THE RELATED ART

Today's food storage containers generally fall into two classes: eitherbulky and reusable, or lightweight but designed for single-usedisposable options. The former is either a glass item that offerstoxin-free storage, but is heavy to carry, or a plastic container, thatmay have toxins and still may be too bulky for practical uses. Thelightweight alternatives are often disposable style bags with a sealedclosure, but are made of a material and/or design specific for singleuse purposes. While some customers do wash and reuse, these lightweightdisposable style bags tend to deteriorate and/or fall apart ratherquickly after first use. Furthermore, they are not designed to withstandmultiple cleanings in the dishwasher or washing machine.

Examples of various storage containers can be found in U.S. Pat. No.8,578,572, entitled “CLOSURE MECHANISM AND METHOD OF CLOSING”; U.S. Pat.No. 8,568,031, entitled “CLICKING CLOSURE DEVICE FOR A RECLOSABLE BAG”;U.S. Pat. No. 8,308,021, entitled “DISPOSABLE STORAGE CONTAINER”; U.S.Pat. No. 8,469,593, entitled “RECLOSABLE BAG HAVING A PRESS TO VENTZIPPER”; U.S. Pat. No. 5,542,766, entitled “WATERPROOF CLOSURE SEAL FORBAGS, CLOTHING AND OTHER USES”, U.S. Pat. No. 8,196,269, entitled“CLOSURE MECHANISM FOR A RECLOSABLE POUCH”, U.S. Pat. No. 8,474,623,entitled “ECOLOGICAL SNACK BAG”; U.S. Pat. No. 7,857,515, entitled“AIRTIGHT CLOSURE MECHANISM FOR A RECLOSABLE POUCH”; U.S. Pat. No.8,197,139, entitled “VALVE AND VALVE STRIP FOR A RECLOSABLE CONTAINER”;and U.S. Pat. No. 8,308,021, entitled “DISPOSABLE STORAGE CONTAINER”.

These and other storage containers currently available on the marketsuffer some or all the aforementioned drawbacks and/or lack certaindesirable properties such as lightweight, flexibility, washability,sealability, reusability, durability, portion/volume control, etc.Consequently, there is room for innovations and improvements in thefield of storage containers.

SUMMARY OF THE DISCLOSURE

Embodiments disclosed herein are directed to lightweight, flexible,washable, sealable, reusable, reclosable, and durable storage containershaving gusseted and specific volume to allow for measuring and controlof portions, snacks, miscellaneous items with the benefits ofcompression and storability when not in use. In some embodiments, such astorage container may be referred to herein as a volume control pouch orstorage bag.

In some embodiments, such a volume control storage bag can include orotherwise incorporate freshness and watertight properties desirable infood and travel storage, addressing a particular need in the art for afood grade durable, reliable, washable, and sealable storage bag.

In some embodiments, the volume control storage bag can be made of athermoplastic material such as food safe, FDA-grade polyethylene vinylacetate (PEVA) blend of ethylene vinyl acetate (EVA) and polyethylene(PE). The ratio of EVA/PE may vary from implementation toimplementation, depending upon the desired properties such as stiffness,flexibility, tear resistance, heat resistance, heat retention, etc. Insome embodiments, the ratio of EVA/PE in the material of a volumecontrol storage bag may range from, for instance, approximately 9 partsof EVA to one part of PE to approximately 7 parts of EVA to 3 parts ofPE. Those skilled in the art will appreciate that different ratios ofEVA/PE may be used. Those skilled in the art will also appreciate thatother materials may be used and/or added. In some embodiments, thematerial of the volume control storage bag may have a minimum thicknessconfigured for allowing hot and cold water washing as well as formultiple reuses. In some embodiments, the volume control storage bag canbe machine washed multiple times in high-heat, providing a highlydesirable reusability.

In some embodiments, the entire volume control storage bag can be madeof the same material, including a unique closure mechanism thatsignificantly improves the sealability over prior storage containers. Insome embodiments, the volume control storage bag can be made of two ormore materials, with the closure mechanism of the volume control storagebag having a first ratio of EVA/PE and a body of the volume controlstorage bag having a second ratio of EVA/PE such that the body of thevolume control storage bag is more flexible than the closure mechanism.

Numerous other materials and combinations thereof may also be suitablefor implementing embodiments of a volume control storage bag disclosedherein.

In some embodiments, the closure mechanism of a volume control storagebag disclosed herein can include a pair of closure elements located ontwo sides of the volume control storage bag. The first closure elementmay include a channel and an elongated member extending along a base ofthe first closure element. The second, complementary closure element mayinclude an elongated member and a channel extending along a base of thesecond closure element. Each channel may have a cross-sectional profileresembling a pair of arms extending from a body. Each elongated membermay have a cross-sectional profile resembling a stud or post.

The cross-sectional profile of the channel is configured to allow thechannel to, when pressed, extend to each side of the elongated member tothereby lock with the elongated member. Both elongated members may havea textured or shaped surface to lock and seal in their correspondingchannels and the channels can fully and securely receive theircorresponding elongated members to lock and thereby create an airtight(and hence waterproof) seal which, in some embodiments, may be referredto as a “double-lock.”

In some embodiments, a method of making a volume control storage bag mayinclude a) manipulating a first material using a first tool to create afirst portion having at least a first closure element, the first closureelement having a channel and an elongated member extending along a baseof the first closure element; b) manipulating a second material using asecond tool to create a second portion having a flat or substantiallyflat surface; c) joining the first portion and the second portion tocreate a first sidewall with the first closure element; d) creating acomplementary first portion having a second closure element, the secondclosure element having an elongated member and a channel extending alonga base of the second closure element; e) joining the complementary firstportion and a complementary second portion to create a second sidewallwith the second closure element; f) aligning the first sidewall and thesecond sidewall such that the first closure element and the secondclosure element together form a double-locking closure mechanism; g)aligning edges of the first sidewall with first edges of a gusset; h)sealing the edges of the first sidewall and the first edges of thegusset; i) aligning edges of the second sidewall with second edges ofthe gusset; and I) sealing the edges of the second sidewall and thesecond edges of the gusset, leaving an opening through thedouble-locking closure mechanism and defining an interior space having aspecific volume.

In some embodiments, the method may further comprise forming a firstcorner seal at a first corner and a second corner seal at a secondcorner of the volume control storage bag. These corner seals canreinforce the double-locking closure mechanism and overall strength anddurability of the volume control storage bag.

In some embodiments, reusability of the volume control storage bag issignificantly improved over prior storage containers due at least inpart to the double-seal construction along the edges of the volumecontrol storage bag. Multiple welded seams with a double wall spacerallow for additional strength on the edges of the volume control storagebag. The gusseted design along with calculated design allows forspecific measurements and volume for the storage of food, snacks andother products/materials.

With healthier living trends from portion control, to toxin/Bisphenol A(BPA) free and waste-free lunch, consumers need a lightweight, durablealternative that allows for daily reuses and washes. Embodiments of avolume control storage bag disclosed herein can address this need andmore. For example, it allows customers to carry lots of small snack bagsin their lunch box, purse or brief case, keeping them airtight andfresh, while not requiring a lot of space. Moreover, it allows customersto adhere to bans and trends for waste-free or boomerang lunch, as itcan easily be washed and reused multiple times. Finally, its reusabilityis not only convenient, but also saves money, replacing dozens of singleuse bags and containers alike.

These, and other, aspects of the disclosure will be better appreciatedand understood when considered in conjunction with the followingdescription and the accompanying drawings. It should be understood,however, that the following description, while indicating variousembodiments of the disclosure and numerous specific details thereof, isgiven by way of illustration and not of limitation. Many substitutions,modifications, additions and/or rearrangements may be made within thescope of the disclosure without departing from the spirit thereof, andthe disclosure includes all such substitutions, modifications, additionsand/or rearrangements.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings accompanying and forming part of this specification areincluded to depict certain aspects of the disclosure. It should be notedthat the features illustrated in the drawings are not necessarily drawnto scale. A more complete understanding of the disclosure and theadvantages thereof may be acquired by referring to the followingdescription, taken in conjunction with the accompanying drawings inwhich like reference numbers indicate like features and wherein:

FIG. 1 depicts an isometric view of an example embodiment of a storagebag with a double-locking closure mechanism, double-seal edges, andreinforced corners.

FIG. 2a depicts a diagrammatic representation of a partial, enlargedcross-sectional view of the double-locking closure mechanism of FIG. 1in a non-occluded state, taken generally along the line 2-2 of FIG. 1.

FIG. 2b depicts a diagrammatic representation of a partial, enlargedcross-sectional view of the double-locking closure mechanism of FIG. 2ain an occluded state.

FIG. 3 depicts a diagrammatic representation of a partial, enlargedcross-sectional view of a double-sealed edge of FIG. 1, taken generallyalong the line 3-3 of FIG. 1.

FIG. 4 is a flow chart illustrating an example of a method for making astorage bag according to some embodiments.

FIGS. 5a-5d depict diagrammatic representations of various corner sealprofiles and corresponding stamps or molds used in manufacturing sameaccording to some embodiments.

FIG. 6 depicts a diagrammatic representation of a portion of a toolingfor forming a corner seal of a volume control storage bag according tosome embodiments.

FIG. 7 depicts a diagrammatic representation of a pair of L-shapedcorner profiles according to some embodiments.

FIGS. 8a-8d depict diagrammatic representations of different cornerconfigurations according to some embodiments.

FIG. 9 depicts a diagrammatic representation of a partial, enlargedcross-sectional view of a corner portion of one example embodiment of avolume control storage bag, taken generally along the line 4-4 of FIG. 8d.

FIG. 10 depicts a diagrammatic representation of a tooling for makingdouble seals along the edges of a volume control storage bag accordingto one embodiment.

FIG. 11 depicts a diagrammatic representation of a tooling forreinforcing a corner of a double-locking closure mechanism of a volumecontrol storage bag with a particularly configured corner seal accordingto one embodiment.

FIG. 12 depicts a diagrammatic representation of a tooling formanufacturing a volume control storage bag according to one embodiment.

FIG. 13 depicts a diagrammatic representation of a tooling formanufacturing a double-locking closure mechanism of a volume controlstorage bag according to one embodiment.

FIG. 14 is a flow chart illustrating an example of a method for making avolume control storage bag according to some embodiments.

FIG. 15 depicts an isometric view of an example of a volume controlstorage bag with a double-locking closure mechanism according to someembodiments.

FIG. 16 depicts a diagrammatic representation of a partial, enlargedcross-sectional view of a bottom portion of the volume control storagebag of FIG. 15, taken generally along the line 16-16 of FIG. 15.

DETAILED DESCRIPTION

The disclosure and various features and advantageous details thereof areexplained more fully with reference to the exemplary, and thereforenon-limiting, embodiments illustrated in the accompanying drawings anddetailed in the following description. It should be understood, however,that the detailed description and the specific examples, whileindicating the preferred embodiments, are given by way of illustrationonly and not by way of limitation. Various substitutions, modifications,additions and/or rearrangements within the spirit and/or scope of theunderlying inventive concept will become apparent to those skilled inthe art from this disclosure.

Referring to FIG. 1, storage bag 15 of material 8 according to onenon-limiting example embodiment may include first and second sidewalls17 and 18, opening 19, ends 13 b, 13 c joined around edges or sides 16a-16 c, and gusset 13 a defined by seals 12 a and 12 b. Closuremechanism 9 may have first closure element 14 a and second closureelement 14 b on sides 6 and 7. First closure element 14 a of a firstportion and second closure element 14 b of a complementary first portionmay extend from first corner 11 a to second corner 11 b and may join oneither side proximate opening 19. First sidewall 17 is formed by joiningthe first portion and a second portion having a flat or substantiallyflat surface via seam 10, overlapping edge to edge along the base of thefirst closure element. Second sidewall 18 is formed by joining thecomplementary first portion and a complementary second portion having aflat or substantially flat surface via seam 10, overlapping edge to edgealong the base of the second closure element. In some embodiments, firstclosure element 14 a may include channel 14 a-1 and elongated member 14a-2. In some embodiments, second closure element 14 b may includeelongated member 14 b-1 and channel 14 b-2.

Closure mechanism 9, first and second sidewalls 17, 18, and double-seal12 define storage means interior space 20. As explained below, whenclosure mechanism 9 is fully sealed across opening 19, storage bag 15can provide an airtight seal such that content in interior space 20 maybe maintained for a desired period of time, such as days, months, oryears. In some embodiments, when fully sealed, storage bag 15 canwithstand at least 10 pounds of pressure or higher, for instance, up to35 pounds of pressure. In one embodiment, storage bag 15 can beapproximately 8.5″×4.75″ in size.

FIG. 2a and FIG. 2b respectively depict closure mechanism 9 in anon-occluded state and an occluded state. Referring to FIG. 2a , channel14 a-1 of first closure element 14 a may have a first locking profilewith arms 1 a-1 b extending from body 1 c, while elongated member 14 b-1of second closure element 14 b may have a second locking profile withstud 2 extending from body 4 c of second closure element 14 a. Stud 2may have a textured surface such as bumps, grooves, or crosswise groovesand may be configured and sized to be securely received by arms 1 a-1 b.The textured surface, size, and/or shape of stud 2 and arms 1 a-1 b maybe configured to provide a tactile sensation and/or audible sensations,such as a series of clicks, as a user draws the fingers along closuremechanism 9 to seal opening 19 of storage bag 15 along the length ofclosure mechanism 9.

First closure element 14 a may further include a third locking profilewith stud 3 extending from body 1 c and second closure element 14 b mayfurther include a fourth locking profile with arms 4 a-4 b extendingfrom body 4 c. Stud 3 may have a textured surface such as grooves andmay be configured and sized to be securely received by arms 4 a-1 b.

As shown in FIG. 2b , when coupled, first closure element 14 a andsecond closure element 14 b form a double lock for closure mechanism 9,with elongated member 14 b-1 of second closure element 14 b securelyreceived by channel 14 a-1 of first closure element 14 a and elongatedmember 14 a-2 of first closure element securely received by channel 14b-2 of second closure element 14 b in a complementary manner. Thoseskilled in the art will appreciate that the configuration and geometryof first and second closure elements 14 a, 14 b and their respectivelocking profiles may vary from implementation to implementation.Therefore, the example embodiment of first closure element 14 a andsecond closure element 14 b shown in FIG. 2a and FIG. 2b is illustrativeand non-limiting.

Furthermore, in this example embodiment, to form first sidewall 17, afirst portion having first closure element 14 a and a second portionhaving a flat or substantially flat surface may be joined or otherwiseaffixed to each other using a thermoplastic weld, a strip of moltenthermoplastic weld material, an adhesive, or any material and/or joiningmethods known to those skilled in the art to form seam 10. To formsecond sidewall 18, a complementary first portion having second closureelement 14 b and a complementary second portion having a flat orsubstantially flat surface may be joined or otherwise affixed to eachother in the same or similar manner. In one embodiment, seam 10 may havea minimum measurement such as 3 mm or approximately 3 mm.

As shown in FIG. 2a and FIG. 2b , first sealing and locking section 21,22 is disposed on elongated member 14 b-1 of second closure element 14 band second sealing and locking section 23, 24 is disposed on elongatedmember 14 a-2 on first closure element 14 a. Elongated member 14 b-1 ofsecond closure element 14 b and elongated member 14 a-2 of first closureelement 14 a are shown to have the widest pressure point Y¹ and thenarrowest locking point Y². First pressure contact points 5 a and 5 b ofchannel 14 a-1 and second pressure contact points 6 a and 6 b of channel14 b-2 may define a distance of X which is to never be greater than Y²in order to have a proper securement of first and second closureelements 14 a, 14 b to create a waterproof seal. As a non-limitingexample, X may be 0.7 mm and Y² may be 0.8 mm.

As shown in FIG. 1, in some embodiments, first and second sidewalls 17,18 may be joined and double-sealed around three edges or sides 16 a-16c. This may be done using plastic welding. Plastic welding refers to aprocess of uniting polymeric materials, generally with the aid of heator any suitable conductive element. Welding of thermoplastics can beaccomplished by first preparing the surfaces of the materials, applyingheat and/or pressure to the materials, and allowing the materials tocool. Other welding methods may also be used.

Referring to FIG. 3, in some embodiments, double welded seams or seals12 a, 12 b may have a minimum width of Z. In some embodiment,reinforcement section or gusset 13 a between double seals 12 a and 12 bmay have a width of W where W is approximately no less than three timesZ. As a non-limiting example, Z may be 0.3 mm and W may be 0.9 mm ormore. In one embodiment, gusset 13 a may have a width of 2 mm orapproximately 2 mm.

FIG. 4 is a flow chart illustrating an example of a method for making astorage bag according to some embodiments. In some embodiments, method40 may include creating a first portion having a first closure element(41), creating a second portion (42), and joining the first portion andthe second portion to create a first sidewall with the first closureelement (43). The first closure element may have a channel and anelongated member similar to channel 14 a-1 and elongated member 14 a-2described above with reference to FIGS. 2a and 2 b.

These steps may be repeated to create a second sidewall with a secondclosure element. The second closure element may have a channel and anelongated member similar to elongated member 14 b-1 and channel 14 b-2described above with reference to FIGS. 2a and 2b . Since the secondclosure element may be complementary to the first closure element, thesame tool and/or mold may be used to create both the first portionhaving the first closure element and a complementary first portionhaving the second closure element that is complementary to the firstclosure element (44). Likewise, the same tool and/or mold may be used tomake the second portion and a complementary second portion. Thecomplementary first portion may be joined with the complementary secondportion in the same or similar manner to create the second sidewall withthe second closure element (45).

The first sidewall and the second sidewall may be aligned (46) such thatthe first closure element and the second closure element together canform a double-locking closure mechanism similar to closure mechanism 9described above. Once properly aligned, a double-seal such asdouble-seal 12 described above can be formed (e.g., using a sealingtool) along three sides of the first and second sidewalls, leaving anopening through the double-locking closure mechanism (47).

If desired, corner seals can be formed at the corners to reinforce thedouble-locking closure mechanism (49). Specifically, a first corner sealmay be created at a first corner of the first sidewall and the secondsidewall, the first corner seal reinforcing a first end of thedouble-locking closure mechanism and a second corner seal may be createdat a second corner of the first sidewall and the second sidewall, thesecond corner seal reinforcing a second end of the double-lockingclosure mechanism.

Referring to FIG. 1, in some embodiments, corner seals 11 c, 11 d mayhave a particular profile created with a corresponding tooling for aspecific application. FIGS. 5a-5d depict diagrammatic representations ofvarious corner seal profiles and corresponding molds used inmanufacturing same according to some embodiments. More specifically,FIG. 5a depicts an example of half-moon corner seal profile 51 andcorresponding half-moon shaped mold or stamp 52. FIG. 5b depicts anotherexample of half-elliptical corner seal profile 53 and corresponding moldor stamp 54. FIG. 5c depicts yet another example of triangular cornerseal profile 55 and corresponding mold or stamp 56. FIG. 4d depicts anexample of square corner seal profile 57 and corresponding mold or stamp58. Numerous other corner seal profiles are also possible. Preferably,corner seals 11 c, 11 d are formed to have half-moon corner seal profile51. An example portion of half-moon shaped mold or stamp 52 is shown inFIG. 6.

Referring to FIG. 6, a corner seal may be created using stamp or mold 60having half-moon shaped cavity 65 arising out of flat surface 61. Inthis example, the back side of half-moon shaped cavity 65 is cutoff toshow a cross-sectional view of mold 60. Mold 60 may be referred to as atop plate. In some embodiments, mold 60 may be part of a tool such ascorner seal reinforcement mold portion 112 of tool 110 shown in FIG. 11.When positioned on top of a base plate having a flat surface such astable 62, mold 60 can create space 63 having a corner seal profile suchas half-moon corner seal profile 51 shown in FIG. 5a . In an RF toolingprocess, the top plate is kept at one charge and the base plate is keptat a different charge. The RF tooling process passes the charge throughthe material. Referring to FIG. 1, to form half-moon corner seal 11 c,arc-shaped stamp 60 may be pressed down onto corner 11 a where bothsidewalls 17, 18 meet an end of double-locking closure mechanism 9. Thepressure pushes the heated material to fill space 63, forming a bubble.In some embodiments, additional material may be injected or otherwiseprovided to fill space 63, ensuring a good seal. This stamping processof the corners (e.g., corners 11 a, 11 b shown in FIG. 1) creates astrong, permanent bonding between the ends of the first and secondclosure elements, the seam between edges of first portions having thedouble-locking closure mechanism and edges of second portions of thesidewalls, and the ends of the double-seal, some examples of which areillustrated in FIGS. 8a -8 d.

As a result of the stamping process, these corners may have a particularcorner profile such as L-shaped corner profile 75 a, 75 b shown in FIG.7. Depending upon implementation details, other corner profiles may alsobe possible, as exemplified in FIGS. 8a -8 d.

FIGS. 8a-8d illustrate various corner profiles that may be formed at acorner of a storage bag (e.g., corner 11 a of storage bag 15 shown inFIG. 1 or corner 181 of volume control storage bag 150 shown in FIG. 15)according to some embodiments.

In FIG. 8a , a partial view of one embodiment of storage bag 15 isshown. In this example, double-locking closure mechanism 9 has firstlock 85 a (e.g., when channel 14 a-1 of first closure element 14 a isinterlocked with elongated member 14 b-1 of second closure element 14 b,as shown in FIG. 2b ) and second lock 85 b (e.g., when elongated member14 a-2 of first closure element 14 a is interlocked with channel 14 b-2of second closure element 14 b, as shown in FIG. 2b ). Corner 80 a isformed (e.g., via a stamping process described above) to securely sealand permanently bond the ends of first lock 85 a and second lock 85 b ofdouble-locking closure mechanism 9, seam 10, and the ends of seals 12 a,13 b, further reinforcing gusset 13 a. In this example, corner 80 a hasa box-shaped (rectangle or square) corner profile.

In FIG. 8b , a partial view of one embodiment of storage bag 15 isshown. In this example, corner 80 b has an L-shaped corner profile, withends 86 a, 86 b of first lock 85 a and second lock 85 b extending intocorner 80 b beyond seal 12 b. In some cases, the L-shaped corner profileof corner 80 b may be caused by a slight shifting of storage bag 15during manufacturing, for instance, as the corner stamping tool is usedrepeatedly and/or when storage bag 15 may not be positioned inside anedge tool correctly. Due to continuous use of the tools, heat may begenerated, causing expansion of the tools which, in turn, affects theprecision profile of corner 80 b. However, as illustrated in FIG. 8b ,the L-shaped corner profile of corner 80 b is within the manufacturingtolerance, allowing corner 80 b to securely seal and permanently bondends 86 a, 86 b of first lock 85 a and second lock 85 b ofdouble-locking closure mechanism 9, seam 10, and the ends of seals 12 a,13 b, further reinforcing gusset 13 a.

In some embodiments, the ends of first lock 85 a and second lock 85 b ofdouble-locking closure mechanism 9 may be further reinforced via acorner seal. This is further illustrated in FIGS. 8c and 8 d.

In FIG. 8c , corner seal 87 may be formed simultaneously with corner 80c or in a separate process after corner 80 c is stamped down. Asdescribed above and illustrated in FIGS. 5a-5d , such a corner seal mayhave various shapes and sizes. In this example, corner seal 87 is formedwith a triangular stamp or mold. One of the advantages of this cornerseal reinforcement feature is that it can avoid micro-fissures at thelink or seal point between sides 6 and 7 of storage bag 15. Suchmicro-fissures can cause leaking. Such leaking can be presented byforming corner seal 87 around the ends of first lock 85 a and secondlock 85 b, as illustrated in FIG. 8 c.

FIG. 8d illustrates another example of corner seal 89. Corner seal 89may have a half-moon profile with a depth “T” based on a width “S”defined by first lock 85 a and second lock 85 b. For example, “T” may bedefined as “≥60% of S.” In some embodiments, “S” may be 7 mm orapproximately 7 mm.

A partial, enlarged cross-sectional view of corner seal 89, takengenerally along the line 4-4 of FIG. 8d , is shown in FIG. 9. In thisexample, corner seal 89 may have a cross-sectional height of “H” definedby a tool such as arc-shaped stamp 60 shown in FIG. 6. In oneembodiment, “H” may be defined by space 63 of arc-shaped stamp 60. FIG.9 shows another embodiment of studs 2 and 3 having a shape and/ortexture that is different from the example shown in FIGS. 2a and 2 b.

FIG. 10 depicts a diagrammatic representation of a tooling for makingdouble seals along the edges of a storage bag according to oneembodiment. In this example, tool 100 can be made of metal and includedouble-edge seam mold portion 102 having first and second edge sealmolds 105 a, 105 b. Tool 100 may further include corner stamp area 104.In one embodiment, tool 100 may be used to create seals 12 a, 12 b,gusset 13 a, and corner 80 a shown in FIG. 8a . To create a corner seal,a separate machine or device such as tool 110 shown in FIG. 11 may beused.

FIG. 11 depicts a diagrammatic representation of a tooling forreinforcing a corner of a double-locking closure mechanism of a storagebag with a particularly configured corner seal according to oneembodiment. In this example, tool 110 includes corner seal reinforcementmold portion 112 having a half-moon, bowl, or dome-like profile.

In some embodiments, a single machine or device may be used tosimultaneously create the seals (e.g., seals 12 a, 12 b), the gusset(e.g., gusset 13 a), the corners (e.g., corners 11 a, 11 b), and thecorner seals (e.g., corner seals 11 c, 11 d). FIG. 12 depicts adiagrammatic representation of such a device according to oneembodiment. In this example, tool 120 includes double-edge seam moldportion 102 having first and second edge seal molds 105 a, 105 b similarto those of tool 100 described above for forming the seals and thegusset as described above. Tool 120 further includes corner stamp area124 having corner seal reinforcement feature mold portion 122 forforming corners with corner seals as described above.

FIG. 13 depicts a diagrammatic representation of a tooling formanufacturing a double-locking closure mechanism of a storage bagaccording to one embodiment. In this example, tool 130 may include metalplate 131. Plate 131 has extrusion opening 132 with shaped forms ormolds 134, 13 a, and 136 b. As an example, place 131 may be used to formfirst and second closure elements 14 a, 14 b described above. Forexample, an extrusion machine pushes or pumps a molten material from oneside of extrusion opening 132 to form first and second closure elements14 a, 14 b on the other side of extrusion opening 132. The extrusionprocess is known to those skilled in the art and thus is not furtherdescribed herein. Other processes such as injection molding may also beused to form closure elements 14 a, 14 b.

FIG. 14 is a flow chart illustrating an example of a method for making avolume control storage bag according to some embodiments. In someembodiments, method 140 may include creating a portion having a firstclosure element (121), creating a second portion (123), and joining thefirst portion and the second portion to create a first sidewall with thefirst closure element (125). The first closure element may have achannel and an elongated member similar to channel 14 a-1 and elongatedmember 14 a-2 described above with reference to FIGS. 2a and 2 b.

These steps may be repeated to create a second sidewall with a secondclosure element. The closure element may have a channel and an elongatedmember similar to elongated member 14 b-1 and channel 14 b-2 describedabove with reference to FIGS. 2a and 2b . Since the second closureelement may be complementary to the first closure element, the same tooland/or mold may be used to create both the first portion having thefirst closure element and a complementary first portion having thesecond closure element that is complementary to the first closureelement (127). Likewise, the same tool and/or mold may be used to makethe second portion and a complementary second portion. The complementaryfirst portion may be joined with the complementary second portion in thesame or similar manner to create the second sidewall with the secondclosure element (129).

The first sidewall and the second sidewall may be aligned (131) suchthat the first closure element and the second closure element togethercan form a double-locking closure mechanism similar to double-lockingclosure mechanism 9 described above. In some embodiments, edges of thefirst sidewall may be aligned with the first edges of a gusset (133). Anexample of a gusset which reinforces the bottom portion of a volumecontrol storage bag is shown in FIG. 15. Once properly aligned, theedges of the first sidewall and the first edges of the gusset may besealed (e.g., using a sealing tool) (135). In one embodiment, a sealsuch as double-seal 12 described above can be formed. Likewise, edges ofthe second sidewall may be aligned with the second edges of the gusset(137) and sealed (139), leaving an opening through the double-lockingclosure mechanism and defining an interior space having a particularvolume (e.g., one cup, 2-cup, pint, half-gallon, gallon, etc.).

If desired, corner seals can be formed at the corners as described aboveto reinforce the double-locking closure mechanism (141). Specifically, afirst corner seal may be created at a first corner of the first sidewalland the second sidewall, the first corner seal reinforcing a first endof the double-locking closure mechanism and a second corner seal may becreated at a second corner of the first sidewall and the secondsidewall, the second corner seal reinforcing a second end of thedouble-locking closure mechanism.

In some embodiments, the volume control storage bag may be made of athermoplastic material. Examples of suitable thermoplastic materials mayinclude include polypropylene (PP), ethylene vinyl acetate (EVA),polyethylene (PE), metallocene-polyethylene (mPE), low densitypolyethylene (LDPE), linear low density polyethylene (LLDPE), ultra-lowdensity polyethylene (ULDPE), biaxially-oriented polyethyleneterephthalate (BPET), high density polyethylene (HDPE), polyethyleneterephthalate (PET), recycled polyethylene terephthalate (RPET),polyethylene vinyl acetate (PEVA) among other polyolefin plastomers andcombinations and blends thereof. Other additives such as colorants, slipagents, and antioxidants, including for example talc, oleamide orhydroxyl hydrocinnamate may also be added as desired.

Embodiments of a volume control storage bag disclosed herein preferablyare made of a food grade material which is Food and Drug Administration(FDA) approved, Bisphenol A (BPA) free, flexible, freezer safe (e.g.,cold resistant up to the operating temperature of a typical freezer suchas 20 degrees Fahrenheit), heat resistant and dishwasher safe (e.g.,heat resistant up to the operating temperature of a typical dishwashersuch as 200 degrees Fahrenheit), lead-free, PVC-free, and/or hand washsafe.

In some embodiments, the first portion, the second portion, theircomplementary first and second portions, and the gusset may be made ofthe same or different thermoplastic material(s). As an example, firstsidewall 170, second sidewall 180, and gusset 173 of volume controlstorage bag 150 shown in FIG. 15 may be made of a first type ofthermoplastic material while double-locking closure mechanism 190 may bemade of a second type of thermoplastic material. In some embodiments,the first type of thermoplastic material may have a thickness of about0.25 mm to 0.35 mm, preferably about 0.30 mm. The second type ofthermoplastic material may have the same or different thickness.

In some embodiments, the first type of thermoplastic material may be EVAor a PEVA blend of EVA and PE. The PEVA blend may comprise 1% to 10% ofPE and 99% to 90% of EVA. The ratio of EVA to PE in a PEVA blenddetermines its stiffness/flexibility. The stiffness of the material mayaffect how easily the double-locking closure mechanism may beclosed/opened. Thus, the ratio of EVA to PE in a PEVA blend may varyfrom application to application, depending upon what degree offlexibility/stiffness is desired. The heat resistance property of a PEVAblend may be manipulated in a similar manner. For example, a PEVA blendwith 99% EVA and 1% PE may have high tear resistance and heatresistance, while a PEVA blend with 70% EVA and 30% PE may be softer,but with less tear resistance and less heat resistance. In someembodiments, a PEVA blend of 90% EVA and 10% PE may provide anon-chlorine PVC alternative to food grade storage bags as PVC is not afood grade material. PEVA bonds to another material that is made out ofeither PE or EVA. Thus, some embodiments of a volume control storage bagdisclosed herein can be formed from any combination of PEVA, EVA, and PEmaterials.

In some embodiments, an organic thermoplastic polymer such as polyetherether ketone (PEEK) may be used. PEEK melts around 343° C. (662° F.) andit is FDA approved food grade material. Since it is relatively stiff, ablend of PEEK including another material or materials may be used. ForPEEK, the thinnest laminate thickness the industry currently has is 1millimeter thick. The thinnest silicon laminate available is eventhicker than the thinnest PEEK laminate. In some embodiments, a blend orcomposition including a 50% PEEK, a 48% EVA, and a 2% PE material may beused. In another blend, a ratio can be 40:20:40 with PEEK added for highheat resistance, EVA added for flexibility and durability, and PE addedfor flexibility.

In dishwasher safe embodiments, 100% silicon material or a differentsuitable blend or a different suitable material may be used. Injectionmolding processes may be used in manipulating a silicon material.

In some embodiments, a volume control storage bag disclosed herein canbe formed from high-density polyethylene (HDPE) or polyethylenehigh-density (PEHD) which is a polyethylene thermoplastic. HDPE may bemade into film (sheets) and bonded to silicon or other plastics or toacrylic etc.

In some embodiments, aesthetics (the look and feel) of a volume controlstorage bag disclosed herein may be varied by using and/or blendingcertain materials. For example, referring to FIG. 15, a thermoplasticmaterial may be formed such that first sidewall 170, second sidewall180, and gusset 173 of storage bag 150 are partially transparent orappear translucent. Alternatively, first and second sidewalls 170, 180and gusset 173 may be made opaque by adding a coloring agent to theblend or by changing ratios of materials in the blend. Likewise,double-locking closure mechanism 190 may be made transparent, opaque,translucent, and/or colored.

As an example, a thermoplastic resin may be directed through anextrusion tool having a mold for forming the first closure element. Theextruded part may be cut to size to create the first portion. Thecomplementary first portion may be extruded in the same or similarmanner. In some embodiments, the first portion (with the first closureelement) and the complementary first portion (with the second closureelement) may be extruded primarily of molten EVA with various amounts ofslip component, colorant, and talc additives in a separate process.

In some embodiments, the first portion and the complementary firstportion may be the same or substantially the same. In some embodiments,the first portion may have a height different than a height of thecomplementary first portion. For example, the first closure element onthe first portion may be taller or shorter than the second closureelement on the complementary first portion.

The same or a different thermoplastic material may be directed through adifferent extrusion tool (e.g., casting film machine) having a mold forforming a sheet or sheets (multi-ply) and then cut to size and/or shapeto form the second portion. In some embodiments, gusset 173 may beformed in the same or similar manner. The second portion may have afirst flat surface that eventually becomes part of the outside of thestorage bag thus made and a second flat surface that eventually formspart of the interior space (e.g., interior space 200 shown in FIG. 15).In some embodiments, the first and second surfaces of the second portionmay be the same or substantially the same. In some embodiments, thefirst and second surfaces of the second portion may be different. Forexample, the first and second surfaces of the second portion may betextured, colored, or otherwise treated differently. In someembodiments, the complementary second portion may be the same orsubstantially the same as the second portion. Referring to FIG. 15, insome embodiments, one or both sidewalls 170, 180 may be embossed orotherwise textured with a pattern, such as a diamond pattern. In someembodiments, an exterior surface of first sidewall 170 and/or secondsidewall 180 may be configured such that a marker may be applied andwiped clean (e.g., using a household cleaning chemical or hot water andsoap).

In further embodiments, the exterior surface of the first sidewall 170and/or the exterior surface of the second sidewall 180 may be configuredto be printed on such as a screen print.

The first portion and the second portion can be aligned and joined toform first sidewall 170 with first closure element 164 a as describedabove, creating seam 160 a at first side 176. Likewise, thecomplementary first portion and the complementary second portion can bealigned and joined to form second sidewall 180 with second closureelement 164 b, creating seam 160 b at second side 177. In someembodiments, radio frequency (RF) welding may be used. RF weldingapplies electricity as a heat element to melt a positive and a negativecharge. RF welding is considered the least expensive type of welding andthe fastest one to manufacture the storage bag described above. Othertools such as a sealing tool may be used.

As described above, first sidewall 170 and second sidewall 180 may bealigned to ensure that first closure element 164 a and second closureelement 164 b together can form double-locking closure mechanism 190which can be the same or similar to double-locking closure mechanism 9described above. In some embodiments, edges 162 a-1, 162 a-2, and 162a-3 of first sidewall 170 may be aligned and sealed with first edges 166a-1, 166 a-2, and 166 a-3 of gusset 173. Likewise, edges 162 b-1, 162b-2, and 162 b-3 of second sidewall 180 may be aligned and sealed withsecond edges 166 b-1, 166 b-2, and 166 b-3 of gusset 173, leavingopening 192 through double-locking closure mechanism 190 and defininginterior space 200 having a particular volume.

To reinforce, a corner seal may be created (e.g., using RF welding via aheat-molded stamp) at each corner of double-locking closure mechanism190 as described above. Each corner seal can be sized to accommodate theheight, width, and depth of the ends of double-locking closure mechanism190. As an example, a corner seal may be 3 millimeters in height, 4 to4½ millimeters in depth, and 9 millimeters in width to accommodate thewidth of double-locking closure mechanism 190 such that the ends ofdouble-locking closure mechanism 190 are securely sealed. The thicknessof the corner seals may be the same as the thickness of double-lockingclosure mechanism 190 when it is closed.

When fully sealed across opening 192, double-locking closure mechanism190 can provide an airtight seal such that content in interior space 200may be maintained for a desired period of time, such as days, months, oryears.

As those skilled in the art can appreciate, multiple dimensions can becalculated and set using F¹, F², and F³ distances to define desiredspecific volumes such as one cup, 2-cup, pint, half-gallon, gallon, etc.A close up view of the bottom portion of volume control storage bag 150is shown in FIG. 16, taken generally along the line 16-16 of FIG. 15. Insome embodiments, all welded or sealed seams along the edges of volumecontrol storage bag 150 may have a minimum width defined by Z, as shownin FIG. 16. In one embodiment, Z may be 3 mm or approximately 3 mm.

In the example of FIG. 16, the edges are welded or sealed via a singleedge seal. In some embodiments, a width Z of the single edge seal may beset based on a volume capacity desired for volume control storage bag150. In some embodiments, RF welding may be configured to obtain a widersealing edge. For example, a volume control storage bag with a 6-cupcapacity may be formed to have a 7 mm width of the single edge seal.Alternatively, a double-seal seam such as double-seal 12 described abovemay be formed to provide sufficient strength to the joint based on thevolume.

In some embodiments, a volume control storage bag may be configured tohave a built-in specific volume of a preset measurement such as one cup.To this end, a marker proximate seam 160 may be used to indicate thepreset measurement. Alternatively, seam 160 may be used as a marker toindicate the preset measurement. Embodiments of a volume control storagebag disclosed herein may be dimensioned and/or shaped for various presetmeasurements such as two-cup, four-cup, and/or six-cup. Multiple markersor ticks may be used to indicate different volume sizes. For example,one embodiment of a volume control storage bag may be configured usingF¹, F², and F³ distances to allow for a volume from a half cup to allthe way to six cups. In some cases, putting a liquid in a volume controlstorage bag may distort the shape of the volume control storage bag dueto its flexible material. To this end, the dimensions of the volumecontrol storage bag may be particularly set to accommodate content inliquid form as well as content in solid form.

The shape of the bottom portion (or base) of a volume control storagebag may be configured based on the desired volume and/or the size of theopening. For example, the base of a volume control storage bag may beconfigured to have a square shape such that a smaller footprint can beobtained as compared to a base having a rectangular shape, or viceversa.

Although the invention has been described with respect to specificembodiments thereof, these embodiments are merely illustrative, and notrestrictive of the invention. The description herein of illustratedembodiments of the invention, including the description in the Summary,is not intended to be exhaustive or to limit the invention to theprecise forms disclosed herein (and in particular, the inclusion of anyparticular embodiment, feature or function within the Summary is notintended to limit the scope of the invention to such embodiment, featureor function). Rather, the description is intended to describeillustrative embodiments, features and functions in order to provide aperson of ordinary skill in the art context to understand the inventionwithout limiting the invention to any particularly described embodiment,feature or function, including any such embodiment feature or functiondescribed in the Summary. While specific embodiments of, and examplesfor, the invention are described herein for illustrative purposes only,various equivalent modifications are possible within the spirit andscope of the invention, as those skilled in the relevant art willrecognize and appreciate. For example, color can be used on tabs at topof the double-locking closure mechanism to help create visualdistinction from the rest of the storage bag, making it easier toidentify the opening and unlock. Color can also be applied to the mainstorage element of the bag, in whole or part, to make it easier to seethe contents and/or to distinguish from single use, disposable stylebags. In addition, color can be used as an organizing element forpacking food, identifying person, or keeping distinct for certain foodsto address food allergies.

As indicated, these modifications may be made to the invention in lightof the foregoing description of illustrated embodiments of the inventionand are to be included within the spirit and scope of the invention.Thus, while the invention has been described herein with reference toparticular embodiments thereof, a latitude of modification, variouschanges and substitutions are intended in the foregoing disclosures, andit will be appreciated that in some instances some features ofembodiments of the invention will be employed without a correspondinguse of other features without departing from the scope and spirit of theinvention as set forth. Therefore, many modifications may be made toadapt a particular situation or material to the essential scope andspirit of the invention.

Reference throughout this specification to “one embodiment”, “anembodiment”, or “a specific embodiment” or similar terminology meansthat a particular feature, structure, or characteristic described inconnection with the embodiment is included in at least one embodimentand may not necessarily be present in all embodiments. Thus, respectiveappearances of the phrases “in one embodiment”, “in an embodiment”, or“in a specific embodiment” or similar terminology in various placesthroughout this specification are not necessarily referring to the sameembodiment. Furthermore, the particular features, structures, orcharacteristics of any particular embodiment may be combined in anysuitable manner with one or more other embodiments. It is to beunderstood that other variations and modifications of the embodimentsdescribed and illustrated herein are possible in light of the teachingsherein and are to be considered as part of the spirit and scope of theinvention.

In the description herein, numerous specific details are provided, suchas examples of components and/or methods, to provide a thoroughunderstanding of embodiments of the invention. One skilled in therelevant art will recognize, however, that an embodiment may be able tobe practiced without one or more of the specific details, or with otherassemblies, methods, components, materials, parts, and/or the like. Inother instances, well-known structures, methods, components, materials,or operations are not specifically shown or described in detail to avoidobscuring aspects of embodiments of the invention. While the inventionmay be illustrated by using a particular embodiment, this is not anddoes not limit the invention to any particular embodiment and a personof ordinary skill in the art will recognize that additional embodimentsare readily understandable and are a part of this invention.

As used herein, the terms “comprises,” “comprising,” “includes,”“including,” “has,” “having,” or any other variation thereof, areintended to cover a non-exclusive inclusion. For example, a process,product, article, or apparatus that comprises a list of elements is notnecessarily limited only those elements but may include other elementsnot expressly listed or inherent to such process, process, article, orapparatus.

Furthermore, the term “or” as used herein is generally intended to mean“and/or” unless otherwise indicated. As used herein, including theclaims that follow, a term preceded by “a” or “an” (and “the” whenantecedent basis is “a” or “an”) includes both singular and plural ofsuch term, unless clearly indicated within the claim otherwise (i.e.,that the reference “a” or “an” clearly indicates only the singular oronly the plural). Also, as used in the description herein and throughoutthe claims that follow, the meaning of “in” includes “in” and “on”unless the context clearly dictates otherwise. The scope of thedisclosure should be determined by the following claims and their legalequivalents.

What is claimed is:
 1. A storage bag consisting of a first part, asecond part, and a third part, wherein each of the first part and thesecond part of the storage bag is formed of a first portion having aclosure element and a second portion having a flat or substantially flatsurface, wherein the first portion and the second portion are joinedalong a base of the closure element of the first portion, wherein theclosure element of the first part has a channel and an elongated memberextending along the base of the closure element of the first part,wherein the closure element of the second part has an elongated memberand a channel extending along the base of the closure element of thesecond part, wherein the channel of the closure element of the firstpart and the elongated member of the closure element of the second partare structured for interlocking with one another, wherein the channel ofthe closure element of the second part and the elongated member of theclosure element of the first part are structured for interlocking withone another, wherein the third part is formed of a single continuousgusset having first edges and second edges that together extend aroundan entire periphery of the single continuous gusset, wherein the firstpart and the third part are joined and double-sealed at three sides ofthe first part along the first edges of the third part, wherein thesecond part and the third part are joined and double-sealed at threesides of the second part along the second edges of the third part,wherein the first part and the second part are joined at ends of theclosure element, and wherein the first part, the second part, and thethird part are dimensioned to define a volume of the storage bag.